Multi-layered cap shingle with enhanced wind performance and method of making same

ABSTRACT

A multi-layer cap shingle for installation along a ridge, hip, or rake of a roof includes a forward exposure area and a rear headlap area. The multi-layer cap shingle includes at least two layers of shingle material, a top layer and a bottom layer each having opposed edges. The layers are bonded together with patches of lamination adhesive adjacent their opposed edges. The bottom layer is configured with a deformation-absorbing mechanism such as a pair of slots extending from a forward edge reawardly inboard of the lamination adhesive patches. When the multi-layer cap shingle is bent over a roof ridge, the slots of the bottom layer of shingle material narrow in width to account for the fact that the bottom layer must bend around an arc of slightly smaller radius than the top layer of shingle material. As a result, the opposed edges of the bottom and top layers of shingle material remain aligned and both edges of the top layer are laminated to the bottom layer to increase wind lift resistance of the installed multi-layer cap shingle.

REFERENCE TO RELATED APPLICATION

Priority is hereby claimed to the filing date of U.S. provisional patentapplication 62/368,058 filed on Jul. 28, 2016, the entire content ofwhich is hereby incorporated by reference.

TECHNICAL FIELD

This disclosure relates generally to architectural asphalt roofingshingles and more specifically to multi-layered cap shingles forcovering a ridge, hip, or rake of a shingled roof to present a look ofthickness and depth.

BACKGROUND

Special cap shingles have long been used in asphalt roofing to cover orcap ridges, hips, and rakes of shingled roofs. When using simplethree-tab shingles, the cap shingles often are cut from full shinglessuch that the individual tabs become the exposure areas of the capshingles along a ridge or hip of a roof. In recent years, so-calledarchitectural shingles have become highly desirable for residentialroofing. Architectural shingles typically are formed of stacked layersof shingle material laminated together, shaped, and shaded to present athicker and more textured look on a roof. For example, the well-known“dragon tooth” shingle design has a lower layer of shingle material withan upper layer bonded thereto to form a two layer shingle. The upperlayer is cut to define irregular tabs known as dragon teeth. This, alongwith strategic shading with protective granules presents anaesthetically pleasing and desirable textured appearance on a roof.

With the growth in popularity of architectural shingles came a demandfor cap shingles that complement the thick textured appearance of a roofcovered with architectural shingles. Such cap shingles could no longersimply be cut from full singles as they had been with simple three-tabshingles. Accordingly, special purpose cap shingles have been developedfor covering ridges, hips, and rakes of a roof. These cap shinglesgenerally also are multi-layered in nature. Some are formed by foldingportions of a blank onto other portions to form multiple layers andprovide increased thickness. In other cases, architectural cap shinglesare fabricated by laminating two or more layers of shingle materialtogether to obtain thickness and the appearance of depth and texturealong a ridge, hip, or rake of a roof.

One issue inherent in multi-layer cap shingles arises from the fact thatthey must be bent to be installed along a ridge, hip, or rake. Since thelayers of such cap shingles lie in slightly different juxtaposed planes,their upper layers must bend around an arc with a slightly larger radiusthan the lower layers. As a result, the layers must be able to move withrespect to one another as the cap shingle is bent to accommodate thedifferent arcs around which they must extend. One solution to thisrequirement has been a multi-layered cap shingle with layers that arelaminated together along only one side. This allows the upper and lowerlayers of the cap shingle to slide with respect to one another when thecap shingle is bent.

While this solution has been somewhat successful, it nevertheless hascertain problems and shortcomings inherent in its construction. It hasbeen discovered, for instance, that cap shingles laminated only on oneside exhibit disappointing wind lift resistance on the side where thelayers are not laminated together. Furthermore, since the layers of thecap shingle slide relative to one another when the shingle is bent, theedges of the shingle on the un-laminated side often become misalignedwhen the cap shingles are installed. More specifically, the layers ofridge cap shingles bent to accommodate a steeper sloped roof slide morerelative to one another when bent than do ridge cap shingles bent toaccommodate a less steeply sloped roof. Since it would not be feasibleto fabricate cap shingles for all possible roof slopes, a compromise isstruck and there is almost always a difference between the alignment ofthe layer edges on the un-laminated sides of installed cap shingles.Also, the layers on the un-laminated side do not always lay flat againstone another. Some consider this unsightly.

A need exist for a multi-layered architectural cap shingle that exhibitssuperior wind lift resistance along both edges of the shingle. A relatedneed exists for a multi-layered cap shingle that retains the same degreeof alignment of the opposed edges of its layers along both edges of theshingle regardless of the angle through which the shingle must be bentto accommodate a particular roof pitch. A need also exists for amulti-layered cap shingle having layers that are flat against oneanother and flush when the shingle is installed. It is to the provisionof a multi-layered cap shingle that addresses these and other needs thatthe present invention is primarily directed.

SUMMARY

Briefly described, a multi-layered cap shingle comprises multiple layersof shingle material laminated together along both edges of the shingle,at least in the exposure area. Lower layers of the shingle have relieffeatures in the form of deformation absorption mechanisms. The relieffeatures allow these lower layers to narrow slightly as the shinglebends around an arc with the upper layers of the shingles bending arounda slightly larger arc than the lower layers. This, in turn, lendsflexibility to the multi-layer shingle allowing it to bend over a ridgeor hip easily as if it had only one layer. Further, the layers remainaligned along both of the opposed edges of the shingle regardless of theslope of a roof being accommodated. Since laminating adhesive bonds thelayers along both side edges of the shingle, at least in the exposureareas, the layers lay flat atop with one another. The upper layer cannotrise up away from the lower layer.

Perhaps most salient, however, is that wind lift resistance is very goodalong both of the exposed side edges of the multi-layer cap shingle. Thedeformation absorption mechanisms that allow the upper layer to bendaround a slightly larger arc than the lower layer may comprise spacedlongitudinal slots formed in the exposure areas of the lower layer.Alternatively, the lower layers may be completely discontinuous and thediscontinuities may be spanned with strips that flex or that bunchtogether when the shingle is bent to absorb relative movement betweenthe layers.

Accordingly, a multi-layer cap shingle is disclosed that has superiorwind lift resistance on all sides, that does not exhibit misalignment ofthe layers along either of the opposed side edges of the layers of theshingle, that has layers that lay flat and flush on one another when theshingle is installed, and that exhibits superior wind resistance. Theseand other features, aspects, and advantages of the multi-layer capshingle of this disclosure will be better appreciated upon review of thedetailed description set forth below taken in conjunction with theaccompanying drawing figures, which are briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective exploded view of a prior art multi-layer capshingle showing the layers adhered on only one side.

FIG. 2 is an end view of the cap shingle of FIG. 1 with the shingleassembled for installation.

FIG. 3 shows the prior art cap shingle of FIGS. 1 and 2 installed alonga ridge cap and illustrates problems and shortcomings of the prior art.

FIG. 4 is a perspective exploded view of a multi-layer cap shingle thatembodies principles of the present invention in one preferred form.

FIG. 5 is a front edge view of the multi-layer cap shingle of FIG. 4assembled for installation.

FIG. 6 is a front edge elevation of the multi-layer cap shingle of FIG.5 as it appears when bent over a ridge of a roof.

FIGS. 7a-7d are plan views of the bottom layer of a multi-layer capshingle according to the invention showing various embodiments of therelief features or deformation-absorbing mechanisms incorporated in thelower layer.

FIG. 8 is a perspective exploded view of a multi-layer cap shingle madeup of three layers and showing incorporation of a deformation-absorbingmechanism in the bottom two layers.

FIG. 9 is a front edge elevation showing another embodiment of amulti-layer cap shingle according to the invention.

FIG. 10 is a front edge elevation showing another embodiment of amulti-layer cap shingle according to the invention.

FIG. 11 is a front edge elevation showing yet another embodiment of amulti-layer cap shingle according to the invention.

DETAILED DESCRIPTION

Reference will now be made to the attached drawing figures, wherein likereference numerals indicate like parts throughout various ones of theviews. FIGS. 1-3 illustrate a typical prior art multi-layer cap shingle.The prior art multi-layer cap shingle 11 includes a top layer of shinglematerial 12 and a bottom layer of shingle material 13 each havingopposed side edges. The top and bottom layers 12 and 13 overlie oneanother and are laminated together along one of their respective edgesby a laminating adhesive 14, which can be asphalt or any otherappropriate adhesive.

The opposite edges of the top and bottom layers are not laminatedtogether so that the layers of shingle material are free to slide withrespect to one another except wherein they are laminated together. Theprior art multi-layer cap shingle, which is generally rectangular inshape, has an exposure area 9 and a headlap area 10 (FIG. 1). When aplurality of multi-layer cap shingles are installed along a ridge, theexposure area of each multi-layer cap shingle overlies the headlap areaof an adjacent one of the multi-layer cap shingles in “piggyback”fashion. Sealant patches 15 may be applied along a forward edge of thebottom layer of shingle material. These sealant patches adhere themulti-layer cap shingle to the underlying headlap area of an adjacentmulti-layer cap shingle when the shingles are installed along a ridge,hip, or rake of a roof.

The prior art multi-layer cap shingle of FIGS. 1-3 is installed along aridge of a roof by being bent around an arc to extend over the ridge.The arc is more extreme for higher pitched roofs such as a 12/12 pitchthan for lower pitched roofs such as an 8/12 pitch. This bending isillustrated in FIG. 3. The top layer and the bottom layer each bend tospan the roof ridge. However, the top layer must extend around an arc ofslightly greater radius and slightly greater length than the bottomlayer since the top layer is further from the axis of curvature. Thepurpose of the un-laminated edges of the top and bottom layers is toaccommodate this difference by allowing the top layer to slide relativeto the bottom layer as the shingle is bent. This is illustrated at 18 inFIG. 3, where the edge of the top layer 12 has become inwardly displacedfrom the edge of the bottom layer 13.

Relative sliding displacement of the top and bottom layers of themulti-layer cap shingle upon installation has long been a problem withprior art multi-layer cap shingles. The top and bottom layers of priorart multi-layer cap shingles are left un-laminated along one edgespecifically to allow for relative sliding movement of the top andbottom layers as they are bent over a roof ridge. However, somedesigners and homeowners consider it unsightly for one edge (thelaminated edge) of the cap shingles to have aligned layers when theopposite edge (the un-laminated edge) has layers that are misalignedalong the edge. Furthermore, the fact that the layers are not laminatedalong one edge renders prior art multi-layer cap shingles less resistantto uplift as a result of wind from the direction of the un-laminatededges. The present invention, detailed below, addresses both of theseproblems.

FIGS. 4-6 illustrate an improved multi-layer cap shingle that embodiesprinciples of the present invention in one exemplary form. Referringfirst to FIG. 4, the multi-layer cap shingle 21 includes a top layer 22of shingle material and a bottom layer 23 of shingle material. Theshingle 21 has an exposure area 20 and a headlap area 25. As istraditional, the headlap area of the multi-layer cap shingle 21 will beoverlapped by the exposure area of an adjacent multi-layer cap shinglein piggyback fashion when a plurality of shingles is installed along theridge of a roof. The bottom and top layers are laminated together bymeans of laminating adhesive 24 positioned between the two layers. Morespecifically, a patch of laminating adhesive 24 is applied between thelayers adjacent the two opposed edges at least in the exposure area 20as shown. Sealant patches 26 may be applied to the lower surface of thebottom layer 23 to adhere the exposure area 20 to the underlying headlaparea of an adjacent multi-layer cap shingle in an installation ofshingles along a ridge.

The bottom layer 23 of the multi-layer cap shingle 21 includes a relieffeature or deformation-absorbing mechanism located between the twopatches of laminating adhesive 24. In the embodiment of FIG. 4, thedeformation-absorbing mechanism is configured as two slots 27 and 28that extend from the forward edge of the bottom layer of shinglematerial rearwardly toward the headlap area 25. In this embodiment,there is no laminating adhesive in the region between the two slots.FIG. 5 is a forward edge plan view of the embodiment of FIG. 4illustrating the top layer 22, the bottom layer 23, laminating adhesivepatches 24, and sealant patches 26. The open ends of the slots 27 can beseen. It should be noted that in FIG. 5 and most of the drawing figures,the thicknesses and spacing of components are exaggerated for clarity.In reality, the top and bottom layers are closely juxtaposed and theshingle material, laminating adhesive, and sealant patches are thinnerthan depicted.

FIG. 6 shows the multi-layer cap shingle 21 being bent around an arc asillustrated by arrows 32 in the manner in which it is bent wheninstalled along the ridge of a roof. As with the prior art describedabove, the top layer must bend around an arc of slightly larger radiusand slightly longer length than the bottom layer. Said another way, thebottom layer must bend around an arc of slightly smaller radius andslightly smaller length. Accordingly, the bottom layer must decrease inwidth slightly if the edges of the two layers are to remain aligned. Inthe illustrated embodiment, both edges of the top and bottom layer arelaminated together with laminating adhesive 24 in the exposure area ofthe cap shingle. Accordingly, these edges are fixed relative to oneanother and cannot become misaligned as the multi-layer cap shingle isbent around the arc.

To absorb the decrease in width, i.e. the deformation, of the bottomlayer 23, the slots 27 and 28 narrow progressively as the multi-layercap shingle 21 is bent. This is indicated by arrows 29 and 31 in FIG. 6.As a result, the multi-layer cap shingle can be bent easily around thearc since the bottom layer becomes slightly narrower during the processand does not resist the bending. In other words, the slots 27 and 28that comprise the deformation-absorbing mechanism absorb the reductionin width of the bottom layer by narrowing as the multi-layer cap shingle21 is bent. As a result, the edges of the top and bottom layers remainaligned with each other regardless of the radius of the arc. Thispresents a more aesthetically pleasing cap shingle installation thantraditional prior art multi-layer cap shingles wherein one edge of thetop layer 22 becomes misaligned with the corresponding edge of thebottom layer 23 as described above.

An additional significant advantage of the multi-layer cap shingle ofthis invention arises from the fact that the bottom and top layers 22and 23 are laminated together with laminating adhesive 24 adjacent bothside edges at least in the exposure area of the cap shingle. As aresult, the multi-layer cap shingle is highly resistant to wind liftalong both of its edges. This, in conjunction with the sealing of theshingle to an underlying shingle by means of sealant patches 26, makesan installation of multi-layer cap shingles very stable and windresistant.

FIGS. 7a-7d show in plan views other examples of how thedeformation-absorbing mechanism in a lower layer of a multi-layer capshingle may be implemented. These examples are not intended to beexhaustive or limiting. Any feature in the bottom layer of themulti-layer cap shingle that permits the bottom layer to narrow in widthshould be construed to be within the scope of the present invention.FIG. 7a shows a bottom layer of shingle material 41 having a surface 42.In this example, two parallel slots 43 and 44 extend from the forwardedge of the bottom layer rearwardly within the exposure area of thelayer. As discussed above, these slots 43 and 44 narrow when amulti-layer cap shingle incorporating the bottom layer 41 is bent aroundan arc to absorb the deformation or narrowing of the bottom layerrelative to the top layer.

Similarly, FIG. 7b illustrates a deformation-absorbing mechanism in theform of two generally trapezoidal cutouts 48 and 49 that widen from theforward edge of the bottom layer 46 in the exposure area. Thisconfiguration can improve the deformation-absorbing capability and/orimprove the flexibility of the multi-layer cap shingle without exposinglarge gaps along the forward edge of the shingle. FIG. 7c shows anexample of a bottom layer 51 of shingle material wherein thedeformation-absorbing mechanism comprises a pair of slots 53 and 54 inthe exposure area of the layer and a pair of slots 56 and 57 in theheadlap area of the layer. The addition of slots 56 and 57 in theheadlap area makes the resulting multi-layer cap shingle lighter andmore easily bent. The slots 53 and 54 in the exposure area increasesflexibility and allows the bottom layer 51 to narrow in width as themulti-layer cap shingle is bent around an arc.

FIG. 7d illustrates another embodiment of the deformation-absorbingmechanism in the form of two curved slots 61 and 62 formed in the bottomlayer 58 within the exposure area. The curve of the slots ispredetermined to follow the amount of deformation experienced by thebottom layer as the multi-layer cap shingle is bent over the ridge of aroof. The bending deformation increases from the center of rotation (theroof ridge point) to the far edge of the multi-layer cap shingle as theshingle is applied. Further, since the shingles are installed inpiggyback fashion, the arc of curvature at the front edge of the shingleis somewhat larger than the arc of curvature at the back edge of theshingle. The curved configuration of the deformation-absorbing mechanismshown in FIG. 7d takes these factors into account such that the bendingdeformation in the bottom layer is completely absorbed without creatingstress points in the bottom layer.

FIG. 8 illustrates a multi-layer cap shingle comprising three layers ofshingle material; a top layer 71, a middle layer 72, and a bottom layer73. The middle layer 72 incorporates the deformation-absorbing mechanismof FIG. 7a comprising spaced slots 74. The bottom layer 73 incorporatesthe deformation-absorbing mechanism of FIG. 7c comprising slots 76 inthe exposure area and slots 77 in the headlap area. The bottom layer 73is laminated to the middle layer in the exposure area by laminatingadhesive 78 and the middle layer 72 is laminated to the top layer bylaminating adhesive 75. When this three-layer cap shingle is bent aroundan arc, the middle layer and the bottom layer narrow in width asnecessary to absorb the resulting relative deformations. The bottomlayer narrows more than the middle layer because each must extend aroundan arc of a different radius and length.

FIGS. 9-11 illustrate further embodiments of a multi-layer cap shingleexemplifying the present invention. FIG. 9 shows a multi-layer capshingle 91 comprising a top layer 92 of shingle material laminated to adiscontinuous bottom layer of shingle material. The discontinuities aredefined by slots that extend completely from the front edge of thebottom layer to the back edge of the bottom layer. The bottom layer thuscomprises a first outer edge portion 93, a central portion 94, and asecond outer edge portion 96. Discontinuities 97 and 98 extend along theentire length of the bottom layer from its forward edge to its rear edgethus separating the three portions. The first edge portion 93 islaminated to the top layer 92 via laminating adhesive 99; the centralportion 94 is laminated to the top layer 92 via laminating adhesive 101;and the second edge portion 96 is laminated to the top layer 92 vialaminating adhesive 99. When the multi-layer cap shingle of thisembodiment is bent around an arc for installation, the discontinuitiesnarrow along the entire length of the bottom layer from front to back.Further, changing arc radius and length from the front to the back ofthe shingle in a piggyback installation is fully compensated. This makesthe multi-layer cap shingle very flexible and adaptable and maintainsthe edges of the bottom layer aligned with the edges of the top layer.

FIG. 10 illustrates yet another embodiment of the present invention. Asin the embodiment of FIG. 9, FIG. 10 illustrates a multi-layer capshingle 106 having a top layer of shingle material 107 and a bottomlayer of shingle material comprising a first edge portion 108, a centralportion 109, and a second edge portion 111 separated by discontinuities112 and 113. The first and second edge portions 108 and 111 arelaminated to the top layer 107 by means of laminating adhesive 114 and116 respectively. Unlike the embodiment of FIG. 9, the central portion109 is not laminated to the top layer 107. Instead, it is attached tothe first and second edge portions by strips of flexible material 117and 118 that span the discontinuities and are bonded to the lower layer.The strips 117 and 118 may be made of any suitably flexible materialsuch as a woven or non-woven fabric, a polymer, rubber, or othermaterial. When the multi-layer cap shingle 106 of FIG. 10 is bent aroundan arc, the flexible strips 117 and 118 flex and deform as necessary toallow the discontinuities to narrow and absorb the narrowing deformationof the bottom layer relative to the top layer.

FIG. 11 illustrates an alternate embodiment of a multi-layer cap shingle121 that is similar to the embodiment of FIG. 10 in that it has a toplayer 122 and a bottom layer made up of first and second edge portions123 and 126 and a central portion 124. In this embodiment, strips ofaccordion-folded material 129 and 131 span the discontinuities andattach the central portion 124 to the edge portions 123 and 126. Whenthe multi-layer cap shingle of this embodiment is bent around an arc,the accordion folded strips 129 and 131 compress as necessary to allowthe discontinuities to narrow and skew as necessary to absorb thedeformation of the bottom layer.

The invention has been described herein in terms of various embodimentsand configurations that represent examples of configurations that theinvention might take and that represent the best modes of carrying outthe invention. It will be understood, however, that a wide range ofadditions, deletions, and modifications, both subtle and gross, mightwell be made to the illustrated embodiments and further that entirelydifferent embodiments may be conceived, all without departing from thespirit and scope of the invention, which id delineated only by theclaims.

What is claimed is:
 1. A multi-layer asphalt cap shingle configured tobe bent around an arc for installation along a ridge, hip, or rake of aroof, the multi-layer asphalt cap shingle comprising: a top layer ofasphalt shingle material having a uniform first thickness, opposed sideedges, an exposure portion terminating in a forward edge of the toplayer, and a headlap portion terminating in a rear edge of the toplayer; a bottom layer of asphalt shingle material underlying the toplayer of asphalt shingle material and having a uniform second thicknesssubstantially the same as the first thickness, opposed side edgessubstantially aligned with the opposed side edges of the top layer ofasphalt shingle material, a forward edge adjacent the forward edge ofthe top layer of shingle material, and a rear edge; the bottom layer ofasphalt shingle material being bonded to the top layer of asphaltshingle material adjacent each of the opposed side edges of the top andbottom layers of asphalt shingle material by an adhesive; at least twospaced apart slots formed completely through the bottom layer of asphaltshingle material and extending from the forward edge of the bottom layerof asphalt shingle material toward the rear edge of the bottom layer ofasphalt shingle material, the at least two spaced apart slots narrowingto allow the bottom layer of asphalt shingle material to deform relativeto the top layer of asphalt shingle material when the multi-layerasphalt cap shingle is bent around an arc so that the opposed edges ofthe top and bottom layers of asphalt shingle material maintain theiralignment and are wind lift resistant as a result of being bondedadjacent each of the opposed side edges of the top and bottom layers ofasphalt shingle material.
 2. A multi-layer asphalt cap shingle asclaimed in claim 1 wherein the at least two spaced apart slots each hasa substantially uniform width.
 3. A multi-layer asphalt cap shingle asclaimed in claim 1 wherein the at least two spaced apart slots have anon-uniform width.
 4. A multi-layer asphalt cap shingle as claimed inclaim 1 wherein each of the at least two spaced apart slots is curved.5. A multi-layer asphalt cap shingle as claimed in claim 4 wherein eachof the at least two spaced apart slots curves from the forward edge ofthe bottom layer of asphalt shingle material toward a side edge of thebottom layer of asphalt shingle material.
 6. A multi-layer asphalt capshingle as claimed in claim 1 wherein each of the at least two spacedapart slots extends to the rear edge of the bottom layer of asphaltshingle material to define a discontinuous bottom layer of asphaltshingle material comprising at least a first portion, a second portion,and a third portion.
 7. A multi-layer asphalt cap shingle as claimed inclaim 6 wherein the first portion, the second portion, and the thirdportion are bonded to the overlying top layer of asphalt shinglematerial.
 8. A multi-layer asphalt cap shingle as claimed in claim 7wherein the first, second, and third portions are bonded to theoverlying top layer of asphalt shingle material with adhesive.
 9. Amulti-layer asphalt cap shingle as claimed in claim 6 further comprisinga deformable material spanning each of the at least two spaced apartslots.
 10. A multi-layer asphalt cap shingle as claimed in claim 9wherein the deformable material comprises a flexible cloth material. 11.A multi-layer asphalt cap shingle as claimed in claim 9 wherein thedeformable material comprises an accordion-folded material.